(a) Remove the rear floor service hole cover. (b) Disconnect the fuel pump connector.

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1 REMOVAL 1. REMOVE REAR SEAT CUSHION ASSEMBLY 2. REMOVE REAR FLOOR SERVICE HOLE COVER (a) Remove the rear floor service hole cover. (b) Disconnect the fuel pump connector. 3. DISCHARGE FUEL SYSTEM PRESSURE HINT: 4. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) 5. REMOVE REAR DECK FLOOR BOX 6. REMOVE REAR NO. 3 FLOOR BOARD 7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL When disconnecting the cable, some systems need to be initialized after the cable is reconnected. 8. REMOVE FUEL TANK MAIN TUBE SUB-ASSEMBLY (a) Remove the tube joint clip and disengage the fuel tank main tube clamp, then pull the fuel tube joint out of the plug of the fuel suction tube assembly.

2 *1 Tube Joint Clip *2 Fuel Tank Main Tube Clamp *3 Fuel Tube Joint *4 O-ring Check that there is no dirt or other foreign objects around the fuel tube joint before disconnecting it. Clean the joint if necessary. It is necessary to prevent mud or dirt from entering the joint. If mud or dirt gets in the joint, the O-rings may not seal properly. Only disconnect the joint by hand. Do not bend, kink or twist the nylon tubes. Protect the contact surfaces by covering it with a plastic bag. 9. REMOVE FUEL PUMP GAUGE RETAINER (a) Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer. SST: Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST. Install SST while pressing the SST claws toward the fuel pump gauge retainer (towards the center of SST). (b) Using SST, loosen the fuel pump gauge retainer. SST: Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result.

3 Loosen the retainer by turning it counterclockwise while holding SST down. Do not allow the claw of the tank suction tube support to slip out of its groove on the fuel tank. HINT: The holes on the fuel pump gauge retainer can be fitted into the tips of SST. (c) Remove the fuel pump gauge retainer while holding the fuel suction tube assembly by hand. 10. REMOVE FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Remove the fuel suction tube assembly with pump and gauge from the fuel tank. Make sure that the fuel sender gauge arm does not bend. (b) Remove the gasket from the fuel tank.

4 DISASSEMBLY 1. REMOVE FUEL SENDER GAUGE ASSEMBLY 2. REMOVE FUEL PUMP (a) Disconnect the connector of the fuel pump harness. (b) Disconnect the fuel pump filter hose. (c) Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws, and remove the fuel filter and fuel pump from the fuel subtank. *1 Fuel Tube *2 Fuel Sub-tank Do not do anything which may separate the fuel tube from either the fuel suction plate or fuel filter assembly, such as applying excessive force to the tube. (d) Using a screwdriver with its tip wrapped in protective tape, disengage the 2 claws and remove the No. 1 fuel suction support.

5 (e) Using a screwdriver with its tip wrapped in protective tape, disengage the 5 claws, and remove the fuel pump filter and fuel pump from the fuel filter. Do not damage the fuel pump filter. Do not remove the suction filter. Do not use either the fuel pump or the suction filter if the suction filter is removed from the fuel pump. (f) Disconnect the fuel pump harness connector. (g) Remove the O-ring and spacer from the fuel pump. *1 O-ring *2 Spacer Be careful not to damage the sealing surface. HINT: If the O-ring still remains in the fuel filter, remove it using a wire tip (1 mm diameter) that is formed as shown in the illustration.

6 INSPECTION 1. INSPECT FUEL PUMP (a) Check the resistance. (1) Using an ohmmeter, measure the resistance according to the value(s) in the table below. Standard Resistance: Tester Connection Condition Specified Condition C (68 F) 0.2 to 3.0 Ω If the result is not as specified, replace the fuel pump. (b) Check fuel pump operation. (1) Apply battery voltage between terminals 1 and 2. Check that the pump operates. These tests must be done quickly (within 10 seconds) to prevent the coil from burning out. Keep the fuel pump as far away from the battery as possible. Always switch the voltage on and off on the battery side, not the fuel pump side. If the pump does not operate, replace the fuel pump. If the pump does not operate, replace the fuel pump.

7 REASSEMBLY 1. INSTALL FUEL PUMP (a) Apply gasoline to a new O-ring. Then install the O-ring and spacer to the fuel pump. *1 O-ring *2 Spacer (b) Connect the fuel pump harness connector. (c) Engage the 5 claws of the fuel pump. Make sure that the O-ring is not cut or pinched during the installation. Engage the claws securely. Do not remove the fuel filter. (d) Engage the 2 claws of the No. 1 fuel suction support.

8 (e) Engage the 2 claws of the fuel suction support and install the fuel filter and the fuel pump onto the fuel sub-tank. (f) Align the groove of the fuel pump filter hose with the cutout of the fuel sub-tank and install the hose. Do not apply excessive force to the fuel tube or the suction support. (g) Connect the connector of the fuel pump harness. 2. INSTALL FUEL SENDER GAUGE ASSEMBLY

9 INSTALLATION 1. INSTALL FUEL SUCTION TUBE ASSEMBLY WITH PUMP AND GAUGE (a) Install a new gasket onto the fuel tank. (b) Install the fuel suction tube assembly with pump and gauge to the fuel tank. *1 Protrusion *2 Notch Make sure that the fuel sender gauge arm does not bend. (c) Align the protrusions of the fuel suction tube assembly with pump and gauge with the notchs of the fuel tank. Ensure that the fuel suction tube gasket is in the correct position. 2. INSTALL FUEL PUMP GAUGE RETAINER (a) While holding the fuel suction tube assembly with pump and gauge by hand, position the fuel pump gauge retainer and tighten it lightly by hand. *1 Lock Point

10 *2 Mark *3 Front of Vehicle Check that the contact surface of the fuel tank retainer is not scratched or damaged, and prevent the entry of foreign objects. (b) Using a 6 mm socket hexagon wrench, set SST to the fuel pump gauge retainer. SST: Hold the fuel suction tube assembly upright by hand to ensure that the fuel suction tube gasket is not moved out of position. Engage the SST claws securely with the fuel pump gauge retainer holes to secure SST. Install SST while pressing the SST claws toward the fuel pump gauge retainer (toward the center of SST). (c) Using SST, align the marks on the fuel tank and fuel pump gauge retainer. *1 Lock Point *2 Starting Point *3 Front of Vehicle SST: Do not use any tools other than specified in this operation. Damage to the fuel pump gauge retainer or the fuel tank may result. Tighten the retainer by turning it clockwise while holding SST

11 down. 3. CONNECT FUEL TANK MAIN TUBE SUB-ASSEMBLY (a) Push the fuel tube joint in the plug of the fuel suction plate, then install the tube joint clip. *1 Tube Joint Clip *2 Fuel Tank Main Tube clamp *3 Fuel Tube Joint *4 O-ring *5 Collars Check that there are no scratches or foreign objects around the connected part of the fuel tube joint and plug before performing this work. Check that the fuel tube joint is securely inserted to the end. Check that the tube joint clip is on the collar of the fuel tube joint. After installing the tube joint clip, check that the fuel tank main tube cannot be pushed out. (b) Connect the fuel pump connector. 4. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL When disconnecting the cable, some systems need to be initialized after the cable is reconnected. 5. INSPECT FOR FUEL LEAK 6. INSTALL REAR FLOOR SERVICE HOLE COVER (a) Install the rear floor service hole cover with new butyl tape.

12 7. INSTALL REAR SEAT CUSHION ASSEMBLY 8. INSTALL REAR NO. 3 FLOOR BOARD 9. INSTALL REAR DECK FLOOR BOX 10. INSTALL REAR NO. 2 FLOOR BOARD (for Separate Type)